Robot Substrate Handling SystemPOP1 (¾ Auto) (Robot + Laytable V2)

Why choose a Robot Substrate Handling System?

�� Range of Load & Unload Options

z Load - manual load 1, 2, 3, or 4 up with left or right-hand lay onto the laytable; substrate transferred to the vacuum table using the unload robot.

z Unload - from the vacuum table to a single or dual stack using the unload robot. Optional features include unloading to inspection tables, cutting tables or to stacks on a conveyor belt.

�� Reduced Handling Time & Faster Changeover

z Robot Substrate Handling Systems reduce the overall cycle time of Onset X printers, offering users improved productivity.

z Pallets can be changed quickly, with printed sheets released to post-print finishing with minimal delay.

�� Supports a Range of POP Substrates & Gauges

z Head effectors designed and manufactured by Inca feature a number of suction cups that can be arranged in a variety of configurations, catering to a wide range of substrate sizes and gauges.

z Distorted (bowed) substrate can be handled1 and comprehensive control of table vacuum level and zoning always ensures a flat surface for maximum print quality.

1 Subject to limitations.

�� Reliability & Accuracy of Substrate Placement

z ABB robots have outstanding position repeatability and excellent path accuracy, permitting accurate and repeatable sheet loading on the vacuum table. This means images can be consistently printed in the same position on the substrate, making post-print finishing easier and more efficient.

�� Multiple Standard Layout Configurations with the Option to Customise

z Standard layout configurations offer a reduced footprint over traditional automation systems. If required, robot positioning and safety systems can be customised (subject to extra cost, delivery and installation time) to further maximise space utilisation.

�� Ease of Use

z Robot Substrate Handling Systems are fully integrated within the Inca GUI, making operation simple with minimal training requirements.

�� Supported by all Onset X Printers

z Robot Substrate Handling Systems are supported from the entry level Onset X1 through to the ultra-high productivity Onset X3.

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‘3/4’ Laytable V283000 Series

Assists manual loading of substrate to vacuum table permitting ‘3/4’

automatic operation - substrate is moved to the vacuum table from the

laytable using the unload robot. Offers accurate and easy loading of a wide

range of substrates for 1, 2, 3 or 4 up printing, left or right hand lay.

Unload RobotABB IRB 660 4 AxisPlaces/removes substrateto/from the vacuum table.

Load (A) and Unload (B) StacksWhen required, palletised substrate stacks are moved

in and out of the load/unload areas using a pallet truck or fork lift. The position of the unload stack(s) can be marked (installation specific). Stack capacity

(height) is subject to limitations.

Unload AreaLight Curtain (shaded)When operating in Automatic and Semi-Automatic modes, entry into the unload area is detected by invisible infra-red light curtains; breaking a curtain will remove power from the drives and stop printer and robot operation.

Protective Hard GuardingProtective hard guarding prevents incursion into the unload area and is installation specific. Protective hard guarding shown in this diagram assumes that the unload area is NOT adjacent to walls (hard guarding MAY NOT be required if wall(s) are present).

Controller CabinetOne or more controller cabinets may be installed (number and position dependent on robot specification).

A

B

Head EffectorThe unload robot is fitted with an appropriate specialised head effector, permitting reliable and effective handling of substrate types conforming to specification.

Typical InstallationShort Edge Unload

A012282

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Long Edge Unload Area

I © 2018 Inca Digital Printers Ltd. I

Unload Robot1

Manufacturer ABB Asea Brown Boveri Ltd.

Model / # Axis IRB 660 / 4 Axis

Max. Height2 2.957 m (116.4 in)

Supply 400-480 V; 3-phase and Protective Earth/Ground; 25 A per phase

Energy Consumption ISO-Cube: 2.7 kW; Normal movements: 3.2 kW

1 Refer to manufacturer’s instructions for full specification including but not limited to dimensions, weight, service requirements (electrical, compressed air, etc.), environmental effects and safety systems.

2 Maximum operational height when installed to recommended specification using 500 mm plinth or base.

Inca Digital Printers Ltd. Head Effectors

Quantity 1 x Unload

Suction Cups 48 (16 adjustable); vacuum activation individually controlled

Vacuum Bars 4 (2 adjustable) Ultrasonic Sensors 2

Compressed Air Pressure 6 bar (88 psi) Volume (at 6 bar) 1.65 m3/minute

Supply 20 mm diameter push fitting

Media & Handling - ¾ Automatic Operation

Supported Media Types1 Foam PVC, PVC sheets, foamboard, corrugated cardboard, display board/cardstock, compressed cardboard, polystyrene, paper, synthetic paper, banner material, corrugated polypropylene, polycarbonate

Number of Sheets2 Up to 4 sheets load and unload with optional collation

Maximum Sheet Size Length (X): 3,220 mm (126.8 in); Width (Y): 1,600 mm (63 in)

Minimum Sheet Size Length (X): 805mm (31.7 in); Width (Y): 800 mm (31.5 in)

Gauge (Thickness)3 Minimum: Media-dependent; Maximum 18 mm (0.71 in)

Maximum Weight4 10 kg (22 lb) Max Distortion5 25 mm (1 in) Distribution 2 kg/m2

Maximum Stack Capacity (Height)

Unload6 High Stack: 1,300 mm (51.2 in)Low Stack: 900 mm (35.4 in)

Table Loading Accuracy Accurate to ± 1 mm (0.039 in)

1 Check media specification and test performance before printing.2 Maximum number of sheets and collation ability dependent on installation layout, head effectors fitted and range

of robotic movement available.3 50 mm (2 in) maximum thickness when operating in manual mode; reduced to 48 mm (1.88 in) with printed shim

& table skin fitted; reduced to 46 mm (1.81 in) with printed shim, standard & adjustable table skin fitted.4 Maximum total of all sheets distributed evenly over table; 20 kg (44 lb) maximum weight when operating in

Manual mode at maximum print speed; 80 kg (176 lb) maximum weight when operating in Manual mode at reduced print speed using maximum table vacuum (speed dependent on substrate).

5 Over maximum sheet size on pallet.6 From floor; pallet + media; height installation specific and may vary due to robot base height and effector depth.

Solid pallet required to ensure accurate ultrasonic sensing.

Configurations Short Edge Unload1 Long Edge Unload

Footprint2 13.84 m x 7.82 m (544.8 in x 307.8 in) 13.13 m x 8.65 m (516.9 in x 340.4 in)

Min. Ceiling Height3 3.2 m (126 in)

1 Figures for High Stack system; Low Stack system also available with reduced footprint at expense of stack height.2 Machine + Robot + Laytable + Hard Guarding; customisation may affect footprint; access space required.3 Provides necessary clearance for unimpeded robotic operation.

Safety System Components and specification are installation specific

Unload Area Light Curtain1

Entry into unload area is detected by an invisible infra-red light curtain; breaking the curtain stops printer and robot operation

Programmable Laser Scanning System2

Configured with multiple exclusion (or safety) zones and controlled by multiple safety scanners to monitor equipment area for presence of (unprogrammed) obstacles and motion

Protective Hard Guarding Protective hard guarding prevents incursion into the unload area

1 Active in Automatic and Semi-Automatic modes only.2 Incursions will stop printer when operating (robot non-operational in Manual mode).

While every reasonable effort has been made to ensure the accuracy and appropriateness of the content of this document, Inca Digital Printers Limited cannot be held responsible for any errors, omissions or consequential loss/damage howsoever caused. The information supplied is subject to change without notice due to on-going design improvement and a unit may differ in detail from that described.

Technical Specification

Vacuum BarsFour vacuum bars (two of which are

adjustable to provide greater support for multiple substrate sizes) are fitted on the

underside of the head effector.

Ultrasonic SensorsThe POP head effector features ultrasonic sensors configured to report effector height above the substrate, permitting fine adjustment during the final moments prior to substrate placement.

Suction Cups Forty eight suction cups (fitted in pairs) are

distributed equally over four vacuum bars on the underside of the head effector and enable

substrate to be handled reliably. Suction is created by vacuum generators operating on

the Venturi effect. Vacuum activation is individually controlled per cup. If a loss of vacuum is detected on the effector,

the sheet is dropped instantly. To provide greater support for multiple substrate

sizes, the position of sixteen cups can be moved along the X axis.Inca Digital Printers Ltd. Head Effector

Point-of-Purchase

Printer

Laytable

L

U

Short Edge Unload

Printer

Laytable

L

U

Long Edge Unload

L Load U Unload

Unload Area Light Curtain

Protective Hard Guarding

Robot Effector

Key

I SR0260 - Robotic Substrate Handling System Datasheet (POP1) (Robot + Laytable V2) I Issue 3 I 5 Mar 2018 I I Inca Digital Printers Ltd I 515 Coldhams Lane, Cambridge, CB1 3JS, UK I T +44 (0)1223 577800 I E sales@incadigital.com I

A SCREEN GA Group Company